SOLARAWARDS2011 SHORTLISTED


THINFAB 42


Oerlikon Solars next generation fab THINFAB will enable total module production cost at or below 0.5€/Wp and a 120 MWp output capacity. Oerlikon recognized that for PV to become a significant source for energy amongst the traditional energy sources, solar power had to become economically viable. With the THINFAB with module manufacturing cost at 0.5€/Wp, energy can be produced at 0.10€/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level. Due to highest equipment availability, reduced process steps in the backend and highly optimized line concept (to balance frontend and backend takt times), Oerlikon Solars THINFAB reaches highest uptime with lowest non-productive time.


Challenge THINFAB addresses the challenge to reduce manufacturing cost by 60%. The first generation of thin film silicon in 2007 allowed modules to be produced at approximately 1.2€/Wp. To reach grid parity level in sunny regions to make solar power economically viable, cost have to cut down to no more than 0.5€/Wp.


Problem Solved


Oerlikon Solars next generation fab THINFAB will enable total module production costs at or below 0.5€/Wp and 120 MWp output capacity. With the THINFAB with module manufacturing cost at or below 0.5€/Wp, energy can be produced at 0.10€/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level.


Noteworthy


The key performance drivers to make solar power economically viable are module efficiency, high productivity of the manufacturing line and low module material costs. Recent champion modules on full scale with over 11% initial efficiency and the world record stable cell efficiency for Micromorph® of over 11.8%


form the foundation for 10 % efficiency in average production. In less than 3 years since the introduction of Micromorph® technology the productivity of an Oerlikon Solar fab has increased more than 100% which helps drive down CAPEX per Wp. The optimization of core equipment, line concept, module design and qualification of new materials drives down costs by simplifying the production steps.


Innovation With Oerlikon Solars THINFAB thin film silicon solar power is economically viable first time. In less than 3 years since the market introduction of Oerlikon Solars Micromorph® technology 2007 in Milan the productivity of an Oerlikon Solar fab has been increased by more than 100% which helps to significantly drive down the CAPEX per Wp. The optimization of module design and qualification of new materials drives down costs and increases the manufacturing robustness by simplifying the production steps. Radical innovations in the core equipment of the end-to-end manufacturing line contribute to the reduction in cost per Wp by offering higher efficiency, higher throughput per capital invested as well as lower energy and material consumption. Oerlikon Solars line concept includes but is not limited to improved central handling system, renewed manufacturing execution system and considers all aspects of material logistics. In a cross-functional approach every detail is optimized for the THINFAB, Oerlikon Solars most advanced turnkey photovoltaic thin film silicon manufacturing line.


Customer Benefits With the THINFAB with module manufacturing cost at or below 0.5€/Wp, energy can be produced at 0.10€/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level. Therefore thin film silicon solar power becomes economically viable first time.


Soitec


Concentrix Concentrating Photovoltaic (CPV) technology


Soitec’s Concentrix Concentrating Photovoltaic (CPV) technology was created at Germany’s Fraunhofer Institute. Every aspect of the technology has been optimized to offer a solution with the most efficient solar energy generation currently available on the market.


Soitec’s CPV modules are built on Concentrix technology. They use Fresnel lenses to concentrate sunlight 500 times and focus it onto small multi-junction solar cells. This technology has helped achieve AC system efficiency increases of 25% in actual operating conditions. This is almost twice as high as the efficiency increases achieved using conventional silicon systems. The first demonstration systems date back to 2005 providing a solid track record with this technology.


Soitec manufactures IEC-certified modules on a fully-automated industrial production line, one of the world’s most modern CPV module manufacturing facilities. The modules, based on a simple, yet robust optical concept, are designed for automated mass production at consistently high quality and module efficiency levels. The high degree of automation also allows the building new production lines on a smart copy basis.


The research for Concentrix technology was developed at Germany’s Fraunhofer ISE. Fraunhofer ISE has conducted research on CPV cells and systems since the mid-1980s. Since 2002, the Institute’s CPV research focus has shifted to the development of CPV manufacturing production technologies compatible with successful industrial commercialization. In 2005, the Institute founded a spin-off, Concentrix Solar, to commercialize the technology. Soitec acquired Concentrix Solar in 2009.


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www.solar-pv-management.com Issue VII 2011


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